Saw Blade

ABSTRACT

A reciprocating saw blade for use with a reciprocating saw includes a body defining a longitudinal axis and an attachment portion. The attachment portion includes a tang and an aperture configured to couple to the reciprocating saw. The saw blade also includes a cutting portion formed on the body. The cutting portion includes a plurality of cutting teeth. Each cutting tooth including a tip, a rake face extending from the tip generally toward the longitudinal axis and at least partially defining a gullet, a relief surface extending from the tip and having a first end that is closer to the attachment portion and a second end that is further from the attachment portion, and a protrusion extending from the second end of the relief surface. The protrusion of each tooth inhibits a nail from entering the gullet and contacting the rake face of an adjacent tooth during cutting operations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/092,498, filed Apr. 22, 2011 by Robert W. Butzen et al.,which claims priority to U.S. Provisional Patent Application No.61/326,812, filed Apr. 22, 2010 by Robert W. Butzen et al. and titled,“PLUNGE POINT GEOMETRY FOR SAW BLADE,” to U.S. Provisional PatentApplication No. 61/326,834, filed Apr. 22, 2010 by Robert W. Butzen etal. and titled, “PLUNGE POINT GEOMETRY FOR SAW BLADE,” and to U.S.Provisional Patent Application No. 61/351,436, filed Jun. 4, 2010 byAustin J. Kazda et al. and titled, “TOOTH FORM FOR SAW BLADE,” theentire contents of each of which are hereby incorporated by reference.

BACKGROUND

The present invention relates to saw blades and, more particularly, tosaw blades for use with power tools.

Saw blades, such as reciprocating saw blades, are used for cutting wood,metal, plastics, and other materials. A saw blade typically includes abody, one or more attachment portions, and a cutting portion. Thecutting portion comprises a plurality of teeth made up of one or moretooth forms. Tooth forms on saw blades are a major factor in thedurability, cost, speed of cutting, and accuracy and quality of cutsmade. Each tooth typically includes a tip, a relief face, a rake face,and a gullet. The teeth are generally separated by a pitch length(otherwise identified as the number of teeth per inch (TPI)). Some toothforms vary along the length of the saw blade or include portions havingvaried teeth. In some tooth forms, a nail may become lodged in thegullet of a tooth during operation, thereby breaking or otherwisedamaging the tooth.

In many instances, the operator of a reciprocating saw uses the saw andattached saw blade to initiate and make cuts in construction materialstarting at an edge, or periphery, of the construction material. Duringsuch cuts, the cutting portion and the plurality of teeth associatedtherewith are the first part of the saw blade to contact the material.In other instances, the operator of the reciprocating saw uses the sawand attached saw blade to initiate a cut in a face of the constructionmaterial (i.e., away from the edge, or periphery, of the constructionmaterial). This type of cut is typically referred to as a plunge cut.During a plunge cut, a leading tooth located proximate the end of thesaw blade penetrates the material face first. Therefore, the endgeometry and the leading tooth geometry of the saw blade are significantto performance during plunge cutting and may affect the durability ofthe saw blade, the speed with which the plunge cut is executed, and theaccuracy of the cut.

SUMMARY

In one embodiment, the invention provides a reciprocating saw blade foruse with a reciprocating saw. The reciprocating saw blade is configuredto cut a work piece having a nail extending therethrough. Thereciprocating saw blade includes a body defining a longitudinal axis andan attachment portion coupled to the body. The attachment portionincludes a tang and an aperture configured to couple to thereciprocating saw. The reciprocating saw blade also includes a cuttingportion formed on the body. The cutting portion includes a plurality ofcutting teeth. Each cutting tooth including a tip, a rake face extendingfrom the tip generally toward the longitudinal axis and at leastpartially defining a gullet, a relief surface extending from the tip andhaving a first end that is closer to the attachment portion and a secondend that is further from the attachment portion, and a protrusionextending from the second end of the relief surface. The protrusion ofeach cutting tooth inhibits the nail from entering the gullet andcontacting the rake face of an adjacent cutting tooth during cuttingoperations.

In another embodiment, the invention provides a reciprocating saw bladefor use with a reciprocating saw. The reciprocating saw blade includes abody defining a longitudinal axis and an attachment portion coupled tothe body. The attachment portion includes a tang and an apertureconfigured to couple to the reciprocating saw. The reciprocating sawblade also includes a cutting portion formed on the body. The cuttingportion includes a plurality of cutting teeth. Each cutting toothincludes a tip, a relief surface extending from the tip, and aprotrusion extending from an end of the relief surface opposite the tip.The tips of the plurality of cutting teeth define a first plane that isgenerally parallel to the longitudinal axis, and the protrusions of theplurality of cutting teeth define a second plane that is generallyparallel to the longitudinal axis. A distance between the first planeand the second plane is at most approximately 0.035 inches.

In yet another embodiment, the invention provides a reciprocating sawblade for use with a reciprocating saw. The reciprocating saw bladeincludes a body defining a longitudinal axis and an attachment portioncoupled to the body. The attachment portion includes a tang and anaperture configured to couple to the reciprocating saw. Thereciprocating saw blade also includes a cutting portion formed on thebody. The cutting portion includes a plurality of cutting teeth. Eachcutting tooth includes a tip, a relief surface extending from the tip,and a protrusion extending from an end of the relief surface oppositethe tip. Each cutting tooth defines an effective relief surface thatextends from the tip and is tangent to the protrusion. A distancebetween effective relief surfaces of adjacent cutting teeth is at mostapproximately 0.06 inches.

In still another embodiment, the invention provides a reciprocating sawblade for use with a reciprocating saw. The reciprocating saw bladeincludes a body defining a longitudinal axis and an attachment portioncoupled to the body. The attachment portion includes a tang and anaperture configured to couple to the reciprocating saw. The attachmentportion is angled relative to the longitudinal axis by a tang angle. Thereciprocating saw blade also includes a cutting portion formed on thebody. The cutting portion includes a plurality of cutting teeth. Eachcutting tooth includes a tip, a relief surface extending from the tip,and a protrusion extending from an end of the relief surface oppositethe tip. Each cutting tooth defines an effective relief surface thatextends from the tip and is tangent to the protrusion. The tips of theplurality of cutting teeth define a plane that is generally parallel tothe longitudinal axis. The relief surface of each cutting toothintersects the plane at a relief angle, and the effective relief surfaceof each cutting tooth intersects the plane at an effective relief angle.The effective relief angle is between the tang angle and the reliefangle.

In yet still another embodiment, the invention provides a reciprocatingsaw blade for use with a reciprocating saw. The reciprocating saw bladeis configured to cut a work piece having a nail extending therethrough.The reciprocating saw blade includes a body defining a longitudinal axisand an attachment portion coupled to the body. The attachment portionincludes a tang and an aperture configured to couple to thereciprocating saw. The attachment portion is angled relative to thelongitudinal axis by a tang angle. The reciprocating saw blade includesa cutting portion formed on the body. The cutting portion includes aplurality of cutting teeth. Each cutting tooth includes a tip, a rakeface extending from the tip generally toward the longitudinal axis andat least partially defining a gullet, a relief surface extending fromthe tip, and a protrusion extending from an end of the relief surfaceopposite the tip. The protrusion of each cutting tooth inhibits the nailfrom entering the gullet and contacting the rake face of an adjacentcutting tooth during cutting operations. Each cutting tooth defines aneffective relief surface that extends from the tip and is tangent to theprotrusion. The tips of the plurality of cutting teeth define a firstplane that is generally parallel to the longitudinal axis, and theprotrusions of the plurality of cutting teeth define a second plane thatis generally parallel to the longitudinal axis. A distance between thefirst plane and the second plane is at most approximately 0.035 inches.A distance between effective relief surfaces of adjacent cutting teethis at most approximately 0.06 inches. The relief surface of each cuttingtooth intersects the first plane at a relief angle and the effectiverelief surface of each cutting tooth intersects the first plane at aneffective relief angle. The effective relief angle is between the tangangle and the relief angle.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a saw blade according to one embodimentof the invention.

FIG. 2 is a side view of the saw blade shown in FIG. 1.

FIG. 3 is an enlarged side view of a portion of the saw blade shown inFIG. 1.

FIG. 4 is an enlarged side view of the portion of the saw blade shown inFIG. 4, the saw blade cutting through a work piece having a nailextending therethrough.

FIG. 5 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 6 is an enlarged side view of a portion of the saw blade shown inFIG. 5.

FIG. 7 is an enlarged side view of a portion of a saw blade according toyet another embodiment of the invention.

FIG. 8 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 9 is an enlarged side view of a portion of the saw blade shown inFIG. 8.

FIG. 10 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 11 is an enlarged side view of a portion of the saw blade shown inFIG. 10.

FIG. 12 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 13 is an enlarged side view of a portion of the saw blade shown inFIG. 12.

FIG. 14 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 15 is an enlarged side view of a portion of the saw blade shown inFIG. 14.

FIG. 16 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 17 is an enlarged side view of a portion of the saw blade shown inFIG. 16.

FIG. 18 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 19 is an enlarged side view of a portion of the saw blade shown inFIG. 18.

FIG. 20 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 21 is an enlarged side view of a portion of the saw blade shown inFIG. 20.

FIG. 22 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 23 is an enlarged side view of a portion of the saw blade shown inFIG. 22.

FIG. 24 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 25 is an enlarged side view of a portion of the saw blade shown inFIG. 24.

FIG. 26 is a side view of a saw blade according to another embodiment ofthe invention.

FIG. 27 is an enlarged side view of a portion of the saw blade shown inFIG. 26.

FIG. 28 is a perspective view of a reciprocating saw.

FIG. 29 is a perspective view of a saw blade according to anotherembodiment of the invention.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

DETAILED DESCRIPTION

FIGS. 1-3 illustrate a saw blade 30 according to one embodiment of theinvention. The illustrated saw blade 30 is a reciprocating saw blade foruse with a power tool such as, for example, a reciprocating saw 34 (FIG.28). The saw blade 30 includes a body 38, an attachment portion 42 forcoupling the blade 30 to the reciprocating saw 34, a cutting portion 46having a plurality of cutting teeth 50, and a plunge point 54 forinitiating a plunge cut. In the illustrated embodiment, the body 38, theattachment portion 42, the cutting portion 46, and the plunge point 54are all integrally formed as a single piece such that the saw blade 30is a unitary structure. In other embodiments, the saw blade 30 may beformed from several pieces that are welded or otherwise securedtogether. During operation, the saw blade 30 is reciprocated in acutting direction 58 and a return direction 62 (FIG. 2) to cut through awork piece. In some embodiments, the saw 34 and the blade 30 may be usedto cut through work pieces composed of wood having nails extendingthrough or embedded therein.

The body 38 includes a first end portion 66 and a second end portion 70.The attachment portion 42 is coupled to (e.g., formed at) the first endportion 66 of the body 38 and the plunge point 54 is coupled to (e.g.,formed at) the second end portion 70 of the body 38. A back portion 74extends between the attachment portion 42 and the plunge point 54 on aside of the body 38 opposite the cutting portion 46. The illustratedback portion 74 includes four stepped surfaces 78, 82, 86, 90 atdifferent distances from the cutting portion 46. The body 38 alsodefines a longitudinal axis 94 (FIGS. 2 and 3) extending through thefirst end portion 66 and the second end portion 70.

The attachment portion 42 extends from the first end portion 66 of thebody 38 and includes a tang 98 and an aperture 102. The tang 98 and theaperture 102 are configured to engage a blade clamp of a reciprocatingsaw to securely and releasably couple the blade 30 to the saw. As shownin FIG. 2, the illustrated attachment portion 42 is angled relative tothe longitudinal axis 94 by a tang angle A. In the illustratedembodiment, the tang angle A is approximately 6.5 degrees. In otherembodiments, the tang angle A may be larger or smaller.

Referring to FIGS. 2 and 3, the cutting teeth 50 define a tooth form onthe body 38. The illustrated tooth form includes five teeth per inch(TPI) such that adjacent cutting teeth 50 are separated by a pitch P of0.2 inches. In other embodiments, the saw blade 30 may include fewer ormore teeth per inch. For example, the tooth form may include 4 TPI, 6TPI, or the like. In the illustrated embodiment, the cutting teeth 50are unset such that the teeth 50 extend straight from the body 38. Inother embodiments, some or all of the teeth 50 may be bent or “set” atvarious angles relative to a hypothetical plane defined by the body 38.The distances and angles identified herein refer to a saw blade in whichthe cutting teeth are unset. However, it should be readily apparent thata saw blade may be designed according to the disclosed dimensions withunset cutting teeth, and the cutting teeth may ultimately be set asdesired during manufacture.

As shown in FIG. 3, each cutting tooth 50 includes a tip 106, a rakeface 110 extending from the tip 106 generally toward the longitudinalaxis 94 and at least partially defining a gullet 114, a relief surface118 extending from the tip 106 and having a first end 122 that is closerto the attachment portion 42 and a second end 126 that is further fromthe attachment portion 42, and a protrusion 130 extending from thesecond end 126 of the relief surface 118. The tips 106 of the cuttingteeth define a plane 134 that is generally parallel to the longitudinalaxis 94.

Each rake face 110 extends from the corresponding tip 106 at a rakeangle B relative to the plane 134. The rake angle B of each cuttingtooth 50, measured through the corresponding cutting tooth 50, is apositive rake angle (i.e., less than 90 degrees). In the illustratedembodiment, the rake angle B of each cutting tooth is approximately 80to 88 degrees. In other embodiments, the rake angle B may be larger orsmaller, or each rake face 110 may extend at a ‘negative rake angle’(i.e., greater than 90 degrees relative to the plane 134).

The gullet 114 of each cutting tooth 50 is defined by the rake face 110of the cutting tooth 50 and a gullet surface 138. Each gullet surface138 extends from the corresponding rake face 110 to the protrusion 130of an adjacent tooth 50 and includes a base 142. The gullet surfaces 138are defined by a first gullet radius r₁, a second gullet radius r₂, anda third gullet radius r₃. In the illustrated embodiment, the firstgullet radius r₁ is approximately 0.021 inches, the second gullet radiusr₂ is approximately 0.035 inches, and the third gullet radius r₃ isapproximately 0.040 inches. The gullet 114 of each tooth 50 also has agullet depth L, or tooth height, measured from the base 142 of thegullet 114 to the tip 106 of the tooth 50. In the illustratedembodiment, the gullet depth L is approximately 0.1 inches.

The relief surface 118 of each cutting tooth 50 extends generally towardthe longitudinal axis 94 and toward the plunge point 54. The reliefsurfaces 118 are oriented at relief angles C relative to the plane 134.In the illustrated embodiment, the relief angle C of each cutting tooth50 is approximately 23 degrees. In other embodiments, the relief anglesC may be larger or smaller. Each relief surface 118 has a relief lengthM measured from the first end 122 (e.g., the tip 106) to the second end126 (e.g., a beginning of the protrusion 130). In the illustratedembodiment, the relief length M of each cutting tooth 50 isapproximately 0.1 inches. In other embodiments, the relief length M maybe larger or smaller.

The relief surface 118 of each cutting tooth 50 is interrupted by theprotrusion 130 extending from the second end 126 of the relief surface118. In some embodiments, the protrusion 130 at the cutting tooth 50nearest the plunge point 54 may be omitted. The protrusion 130 of eachtooth 50 is defined by a first protrusion radius r₄ that transitionsfrom the relief surface 118, a first protrusion face 146 that extendsfrom the first protrusion radius r₄, an apex 150 that extends from thefirst protrusion face 146 and has a second protrusion radius r₅, and asecond protrusion face 154 extending from the apex 150 to the gulletsurface 138. In the illustrated embodiment, the apex 150 of eachprotrusion 130 is curved such that the protrusions 130 are generallyrounded. In other embodiments, the protrusions 130 may have other shapesor forms. The second protrusion face 154 is disposed at an internalprotrusion angle D relative to the first protrusion face 146 and isdisposed at a rear protrusion angle E relative to the plane 134. In theillustrated embodiment, the first protrusion radius r₄ is approximately0.012 inches, the second protrusion radius r₅ is approximately 0.010inches, the internal protrusion angle D is approximately 70 degrees, andthe rear protrusion angle E is approximately 80 degrees.

With continued reference to FIG. 3, the protrusion 130 of each cuttingtooth 50 is spaced a first distance N, measured generally parallel tothe longitudinal axis 94, from the tip 106 of the corresponding cuttingtooth 50. The protrusion 130 of each cutting tooth 50 is spaced a seconddistance O, measured generally parallel to the longitudinal axis 94,from the tip 106 of an adjacent cutting tooth 50. The second distance Oalso represents a width of the gullet 114. In some embodiments, a ratiobetween the first distance N and the second distance O is approximately1.5. In the illustrated embodiment, the first distance N isapproximately 0.12 inches and the second distance O is approximately0.08 inches.

The apex 150 of the protrusion 130 is spaced a distance Q, measuredgenerally perpendicular to the longitudinal axis 94, from the base 142of the gullet 114. In some embodiments, a ratio between the distance Qfrom the base 142 of the gullet 114 to the apex 150 of the protrusion130 and the distance L from the base 142 of the gullet 114 to the tip106 of the cutting tooth 50 is approximately 0.68. In the illustratedembodiment, the distance Q is approximately 0.068 inches.

The protrusions 130 of the cutting teeth 50 define a plane 158 that isgenerally parallel to the longitudinal axis 94 and to the plane 134defined by the tips 106 of the cutting teeth 50. In some embodiments, adistance R between the plane 134 defined by the tips 106 and the plane158 defined by the protrusions 130 is at most approximately 0.035inches. In the illustrated embodiment, the distance R is approximately0.032 inches. Such an arrangement helps inhibit nails from entering thegullets 114 of the cutting teeth 50 during cutting operations, asfurther discussed below.

Each cutting tooth 50 also defines an effective relief surface 162 thatextends from the tip 106 of the cutting tooth 50 and is tangent to theadjacent/respective protrusion 130. Each effective relief surface 162intersects the plane 134 defined by the tips 106 at an effective reliefangle F. In the illustrated embodiment, the effective relief angle F isapproximately 14.5 degrees. The effective relief angle F is between thetang angle A and the relief angle C. That is, the effective relief angleF of each cutting tooth 50 is generally greater than the tang angle A(e.g., 6.5 degrees), but generally smaller than the relief angle C(e.g., 23 degrees). In some embodiments, a ratio between the reliefangle C and the effective relief angle F of each cutting tooth 50 isapproximately 1.6.

The effective relief surfaces 162 of adjacent cutting teeth 50 arespaced apart from each other by a distance S. In some embodiments, thedistance S between effective relief surfaces 162 is at mostapproximately 0.06 inches. In the illustrated embodiment, the distance Sis approximately 0.05 inches. Such an arrangement also helps inhibitnails from entering the gullets 114 of the cutting teeth 50 duringcutting operations, as further discussed below. In some embodiments, aratio between the effective relief angle F, in degrees, of each cuttingtooth 50 and the distance S, in inches, between effective reliefsurfaces 162 is approximately 290. Furthermore, in some embodiments, aratio between the distance O from the protrusion 130 of one cuttingtooth 50 to the tip 106 of an adjacent cutting tooth 50 and the distanceS between effective relief surfaces 162 of adjacent cutting teeth 50 isapproximately 1.6.

Referring to FIG. 4, the protrusions 130 of the cutting teeth 50 inhibitnails 166, or other hard objects, imbedded in a work piece 170 fromentering the gullets 114 and contacting the rake faces 110 of the teeth50 during cutting operations. As the saw blade 30 moves in the cuttingdirection 58 (to the left in FIG. 4), the tips 106 of the cutting teeth50 engage and cut through the work piece 170. The protrusions 130 arehidden behind the tips 106 of adjacent teeth 50 such that theprotrusions 130 do not cut the work piece 170 during the cuttingoperation.

When the saw blade 30 encounters the nail 166, the rake faces 110 of thecutting teeth 50 typically would contact the nail 166. Such contact maychip, break, or otherwise damage the cutting teeth 50, significantlyreducing the usable life of the saw blade 30. However, as shown in FIG.4, the protrusions 130 inhibit the nail 166 from impacting the rakefaces 110. Instead, as the saw blade 30 moves in the cutting direction58, the nail 166 contacts one of the protrusions 130 before contactingthe adjacent rake face 110. The protrusion 130 displaces (e.g., lifts)the saw blade 30, which repositions the nail 166 with respect to thegullet 114 in an improved cutting position. In the improved cuttingposition, the protrusion 130 inhibits the nail 166 from entering thegullet 114 and the tip 106 is allowed to cut into the nail 166. When thesaw blade 30 is reciprocated in the return direction 62 (to the right inFIG. 4), the nail 166 can ride along the corresponding relief surface118 and over the tip 106.

In the illustrated embodiment, the protrusions 130 of the cutting teeth50 are designed to inhibit a standard framing nail having a 0.131 inchdiameter from entering the gullets 114. In other embodiments, theprotrusions 130 may be optimized to inhibit other size nails fromentering the gullets 114. The distance R between the plane 134 definedby the tips 106 and the plane 158 defined by the protrusions 130 and thedistance S between effective relief surfaces 162 of adjacent cuttingteeth 50 are optimized to increase durability of the cutting teeth 50 byoffsetting a center of the framing nail approximately 0.031 inches belowthe plane 134. That is, the protrusions 130 are sized and positioned toprevent approximately 80% of the nail from entering the area above theplane 134. Such a configuration results in an increase in durabilitycompared to a similar saw blade without protrusions on the cuttingteeth. As used herein, the term ‘durability’ refers to the averagenumber of cuts a saw blade makes before fracturing a cutting tooth.

Referring back to FIG. 3, the plunge point 54 is formed on the secondend portion 70 of the body 38 opposite the attachment portion 42. Theillustrated plunge point 54 includes a leading tooth 174 and a secondtooth 178. The leading tooth 174 includes a tip 182, a rake face 186extending from the tip 182 generally toward the longitudinal axis 94 andat least partially defining a leading gullet 190, and a relief surface194 extending from the tip 182 to an end 198 of the body 38. In theillustrated embodiment, the end 198 of the body 38 is generally rounded.In other embodiments, the end 198 of the body 38 may be, for example, asharp point or a flat edge. A top edge 202 extends from the end 198 tothe back portion 74 of the body 38. The top edge 202 is oriented at anangle G relative to the back portion 74 (e.g., relative to the fourthstepped surface 90). In the some embodiments, the angle G may beapproximately 5 to 50 degrees. In the illustrated embodiment, the angleG is approximately 40 degrees.

The tip 182 of the leading tooth 174 extends to the plane 134 defined bythe tips 106 of the cutting teeth 50 to help define the plane 134. Therake face 186 extends from the tip 182 at a leading rake angle Hrelative to the plane 134. The leading rake angle H, measured throughthe leading tooth 174, is a negative rake angle (i.e., greater than 90degrees) such that the leading tooth 174 is a negative rake tooth. Anegative rake tooth is less likely to hook or grab material being cut,allowing the plunge point 54 to more easily penetrate a work piecewithout chipping the work piece. In the illustrated embodiment, theleading rake angle H is approximately 95 to 105 degrees. In otherembodiments, the leading rake angle H may be larger or smaller, or therake face 186 may extend at a positive rake angle relative to the plane134.

The relief surface 194 of the leading tooth 174 extends from the tip 182at a leading relief angle I relative to the plane 134. In someembodiments, the leading relief angle I is less than 90 degrees. Inother embodiments, the leading relief angle I is greater than 45degrees. In the illustrated embodiment, the leading relief angle I isapproximately 55 to 65 degrees.

The leading gullet 190 is defined by the rake face 186 of the leadingtooth 174 and extends to the nearest, or first, cutting tooth 50. Asshown in FIG. 3, the leading gullet 190 is significantly larger than thegullets 114 of the cutting teeth 50 and has a leading gullet width T. Insome embodiments, the leading gullet 174 is at least twice as large aseach gullet 114. In the illustrated embodiment, the leading gullet 174is approximately four times larger than each gullet 114. As such, theleading tooth 174 is spaced further apart from the nearest cutting tooth50 than the cutting teeth 50 are spaced apart from each other. In theillustrated embodiment, a ratio between a distance U from the tip 182 ofthe leading tooth 174 to the tip 106 of the nearest cutting tooth 50,measured generally parallel to the longitudinal axis 94, and thedistance P between the tips 106 of adjacent cutting teeth 50 (i.e., thetooth pitch) is approximately 2.0. The enlarged leading gullet 190improves plunge cut performance by allowing the leading tooth 174 topenetrate further into a work piece before the plurality of cuttingteeth 50 engage the work piece, thereby improving cut quality andfinish. The enlarged leading gullet 190 also improves cut speed byallowing for greater chip removal.

The illustrated second tooth 178 is generally V-shaped and includes atip 206, a rake face 210 extending from the tip 206 generally toward thelongitudinal axis 94, and a relief surface 214 extending from the tip206 generally toward the leading tooth 174. Similar to the leading tooth174, the rake face 210 of the second tooth 178 extends at a negativerake angle J (i.e., at an angle greater than 90 degrees) relative to theplane 134. In the illustrated embodiment, the rake angle J, measuredthrough the second tooth, is approximately 95 to 105 degrees. In otherembodiments, the rake angle J may be larger or smaller, or the rake face210 may extend at a positive rake angle relative to the plane 134.

The second tooth 178 is positioned within the leading gullet 190adjacent the leading tooth 174 such that the second tooth 178 is closerto the leading tooth 174 than to the nearest cutting tooth 50. In theillustrated embodiment, the tip 206 of the second tooth 178 is spaced adistance V, measured generally parallel to the longitudinal axis 94,from the tip 182 of the leading tooth 174. A ratio between the distanceV from the tip 182 of the leading tooth 174 to the tip 206 of the secondtooth 178 and the distance P between the tips 106 of adjacent cuttingteeth 50 (i.e., the tooth pitch) is approximately 0.3. In addition, aratio between the distance U from the tip 182 of the leading tooth 174to the tip 106 of the nearest cutting tooth 50 and the distance V fromthe tip 182 of the leading tooth 174 to the tip 206 of the second tooth178 is approximately 6.6. In other embodiments, these ratios may berelatively larger or smaller.

The illustrated second tooth 178 is generally smaller than the leadingtooth 174 and each of the cutting teeth 50. As shown in FIG. 3, thesecond tooth 178 extends from the leading gullet 190 and is spaced apartfrom the plane 134 defined by the tips 106 of the cutting teeth 50. Inother words, the plane 134 does not intersect or extend through anyportion of the second tooth 178. In the illustrated embodiment, thesecond tooth 178 extends less than halfway from the body 38 to the plane134. In other embodiments, the second tooth 178 may extend to a positionnearer the plane 134 such as, for example, three-quarters the distanceto the plane 134.

In addition, the second tooth 178 has an utmost width W that is lessthan an utmost width X of the leading tooth 174 and an utmost width Y ofeach cutting tooth 50. As used herein, the term ‘utmost width’ refers toa measurement of a tooth that is taken generally parallel to thelongitudinal axis 94 at the tooth's greatest or maximum dimension. Inthe illustrated embodiment, the utmost width X of the leading tooth 174is also less than the utmost width Y of each cutting tooth 50. In otherembodiments, the utmost width X of the leading tooth 174 may be the sameor similar to the utmost width Y of each cutting tooth 50.

The second tooth 178 improves plunge cut performance by breaking up chipmaterial, thereby reducing the load on the leading tooth 174 andfacilitating chip removal. Such an arrangement also increases cuttingspeed and saw blade life. In the illustrated embodiment, the plungepoint 54 includes a single second tooth 178 positioned within theleading gullet 190. In other embodiments, the plunge point 54 mayinclude multiple second teeth positioned within the leading gullet 190.In such embodiments, one or more of the second teeth may be set.Additionally or alternatively, the second teeth may have differentgeometries and/or sizes. In still other embodiments, the second tooth178 may be omitted from the plunge point 54.

FIGS. 5-6 illustrate a reciprocating saw blade 230 according to anotherembodiment of the invention. The illustrated saw blade 230 is similar tothe saw blade 30 described above with reference to FIGS. 1-4, andsimilar parts have been given the same reference numbers, plus 200.

The illustrated saw blade 230 includes a body 238, an attachment portion242 for coupling the blade 230 to a reciprocating saw, a cutting portion246 having a plurality of cutting teeth 250, and a plunge point 254 forinitiating a plunge cut. Each of the cutting teeth 250 includes aprotrusion 330 that inhibits a nail from entering a gullet 314 andcontacting a rake face 310 of an adjacent cutting tooth 250. In theillustrated embodiment, a back portion 274 of the body 238 is formedwith three stepped surfaces 278, 282, 286, rather than the four steppedsurfaces 78, 82, 86, 90 shown in FIGS. 1-2.

FIG. 7 illustrates a cutting portion 446 of a saw blade 430 according toanother embodiment of the invention. The illustrated saw blade 430 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers plus 400.

The cutting portion 446 includes a plurality of cutting teeth 450. Eachcutting tooth 450 includes a protrusion 530 that inhibits a nail fromentering a gullet 514 and contacting a rake face 510 of an adjacentcutting tooth 450. Similar to the gullets 114 and the protrusions 130discussed above with reference to FIGS. 1-4, each of the gullets 514 isdefined by three gullet radii r₁, r₂, r₃ and each of the protrusions 130is defined by two protrusion radii r₄, r₅. In the illustratedembodiment, the first gullet radius r₁ is approximately 0.021 inches,the second gullet radius r₂ is approximately 0.035 inches, the thirdgullet radius r₃ is approximately 0.040, the first protrusion radius r₄is approximately 0.012 inches, and the second protrusion radius r₅ isapproximately 0.010 inches.

In addition, each cutting tooth 450 includes a relief surface 518extending from a tip 506 of the tooth 450. The relief surfaces 518 areoriented at a relief angle C relative to a plane 534 defined by the tips506 of the cutting teeth 450. In the illustrated embodiment, the reliefangle C of each cutting tooth 450 is approximately 26 degrees.

FIGS. 8-9 illustrate a reciprocating saw blade 630 according to anotherembodiment of the invention. The illustrated saw blade 630 is similar tothe saw blade 30 described above with reference to FIGS. 1-4, andsimilar parts have been given the same reference numbers, plus 600.

The illustrated saw blade 630 includes a body 638, an attachment portion642 for coupling the blade 630 to a reciprocating saw, a cutting portion646 having a plurality of cutting teeth 650, and a plunge point 654 forinitiating a plunge cut. Each of the cutting teeth 650 includes a tip706, a rake face 710 at least partially defining a gullet 714, a reliefsurface 718, and a protrusion 730. The protrusions 730 inhibit nailsfrom entering the gullets 714 and contacting the rake faces 710 ofadjacent cutting teeth 650. Each rake face 710 extends from the tip 706at a rake angle B relative to a plane 734 defined by the tips 706. Inthe illustrated embodiment, the rake angle B of each cutting tooth 650is approximately 82 degrees. Each relief surface 718 also extends fromthe tip 706 at a relief angle C relative to the plane 734. In theillustrated embodiment, the relief angle C of each cutting tooth 650 isapproximately 20 degrees.

FIGS. 10-11 illustrate a reciprocating saw blade 830 according toanother embodiment of the invention. The illustrated saw blade 830 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 800.

The illustrated saw blade 830 includes a body 838, an attachment portion842 for coupling the blade 830 to a reciprocating saw, a cutting portion846 having a plurality of cutting teeth 850, and a plunge point 854 forinitiating a plunge cut. Each of the cutting teeth 850 includes aprotrusion 930 that inhibits a nail from entering a gullet 914 andcontacting a rake face 910 of an adjacent cutting tooth 850. Similar tothe gullets 914 discussed above with reference to FIGS. 1-4, each of thegullets 914 is defined by three gullet radii r₁, r₂, r₃. In theillustrated embodiment, the first gullet radius r₁ is approximately0.025 inches, the second gullet radius r₂ is approximately 0.035 inches,and the third gullet radius r₃ is approximately 0.040 inches.

Each of the illustrated protrusions 930 is defined by a first protrusionradius r₄, a second protrusion radius r₅, and a first intermediatesurface 1018 extending between the radii r₄, r₅. The first intermediatesurface 1018 is a generally planar surface. In the illustratedembodiment, the first protrusion radius r₄ is approximately 0.010inches, the second protrusion radius r₅ is approximately 0.010 inches,and the length of the first intermediate surface 1018 is approximately0.005 inches. Each of the protrusions 930 is also defined by a firstprotrusion face 946 that extends from the second protrusion radius r₅,an apex 950 that extends from the first protrusion face 946, and asecond protrusion face 954 that extends from the apex 950 and definesthe gullet 914. The apex 950 is further defined by a third protrusionradius r₆, a fourth protrusion radius r₇, and a second intermediatesurface 1022 extending between the radii r₆, r₇. The second intermediatesurface 1022 is a generally planar surface. In the illustratedembodiment, the third protrusion radius r₆ is approximately 0.010inches, the fourth protrusion radius r₇ is approximately 0.010 inches,and the length of the second intermediate surface 1022 is approximately0.005 inches.

FIGS. 12-13 illustrate a reciprocating saw blade 1030 according toanother embodiment of the invention. The illustrated saw blade 1030 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 1000.

The illustrated saw blade 1030 includes a body 1038, an attachmentportion 1042 for coupling the blade 1030 to a reciprocating saw, acutting portion 1046 having a plurality of cutting teeth 1050, and aplunge point 1054 for initiating a plunge cut. Each of the cutting teeth1050 includes a protrusion 1130 that inhibits a nail from entering agullet 1114 and contacting a rake face 1110 of an adjacent cutting tooth1050. Similar to the gullets 1114 discussed above with reference toFIGS. 1-4, each of the gullets 1114 is defined by three gullet radii r₁,r₂, r₃. In the illustrated embodiment, the first gullet radius r₁ isapproximately 0.030 inches, the second gullet radius r₂ is approximately0.035 inches, and the third gullet radius r₃ is approximately 0.040inches.

Each of the illustrated protrusions 1130 is defined by a firstprotrusion face 1146 extending from a relief surface 1118, an apex 1150,and a second protrusion face 1154 that extends from the apex 1150 anddefines the gullet 1114. In the illustrated embodiment, the apex 1150 isa pointed tip such that each protrusion 1130 is generally pointed,rather than rounded. The apexes 1150 define a plane 1158 that is spacedapart a distance R from a plane 1134 defined by tips 1106 of the cuttingteeth 1050. In the illustrated embodiment, the distance R isapproximately 0.034 inches. Furthermore, each apex 1150 is spaced aparta distance O from the tip 1106 of an adjacent cutting tooth 1050. In theillustrated embodiment, the distance O is approximately 0.07 inches. Insuch embodiments, a ratio between a distance N from the protrusion 1130to the tip 1106 of one cutting tooth 1050 and the distance O isapproximately 1.9. In other embodiments, the distances R, O may berelatively larger or smaller, such as, for example, 0.032 inches and0.08 inches, respectively.

FIGS. 14-15 illustrate a reciprocating saw blade 1230 according toanother embodiment of the invention. The illustrated saw blade 1230 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 1200.

The illustrated saw blade 1230 includes a body 1238, an attachmentportion 1242 for coupling the blade 1230 to a reciprocating saw, acutting portion 1246 having a plurality of cutting teeth 1250, and aplunge point 1254 for initiating a plunge cut. In the illustratedembodiment, the plunge point 1254 includes a leading tooth 1374, but nota second tooth. The leading tooth 1374 includes a tip 1382, a rake face1386 extending from the tip 1382 and at least partially defining aleading gullet 1390, and a relief surface 1394 extending from the tip1382 to an end 1398 of the body 1238. The rake face 1386 extends fromthe tip 1382 at a leading rake angle H relative to a plane 1334 definedby tips 1306 of the cutting teeth 1250. The leading rake angle H,measured through the leading tooth 1374, is a negative rake angle suchthat the leading tooth 1374 is a negative rake tooth. In the illustratedembodiment, the leading rake angle H is approximately 95 to 105 degrees.

As shown in FIG. 15, the tip 1382 of the leading tooth 1374 is spaced adistance U from the tip 1306 of the nearest cutting tooth 1250. In theillustrated embodiment, the distance U is generally the same as adistance P (i.e., the pitch) between the tips 1306 of adjacent cuttingteeth 1250. As such, the leading gullet 1390 is generally the same sizeas gullets 1314 defined by the plurality of cutting teeth 1250.

Although not shown, in some embodiments, each of the cutting teeth 1250may include a protrusion that inhibits a nail from entering the gullet1314 and contacting a rake face 1310 of an adjacent cutting tooth 1250.

FIGS. 16-17 illustrate a reciprocating saw blade 1430 according toanother embodiment of the invention. The illustrated saw blade 1430 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 1400.

The illustrated saw blade 1430 includes a body 1438, an attachmentportion 1442 for coupling the blade 1430 to a reciprocating saw, acutting portion 1446 having a plurality of cutting teeth 1450, and aplunge point 1454 for initiating a plunge cut. In the illustratedembodiment, the plunge point 1454 includes a leading tooth 1574, but nota second tooth. The leading tooth 1574 includes a tip 1582, a rake face1586 extending from the tip 1582 and at least partially defining aleading gullet 1590, and a relief surface 1594 extending from the tip1582 to an end 1598 of the body 1438. The rake face 1586 extends fromthe tip 1582 at a leading rake angle H relative to a plane 1534 definedby tips 1506 of the cutting teeth 1450. The leading rake angle H,measured through the leading tooth 1574, is a positive rake angle suchthat the leading tooth 1574 is a positive rake tooth havingsubstantially the same rake angle as each of the cutting teeth 1450. Inthe illustrated embodiment, the leading rake angle H is approximately 80to 88 degrees.

The relief surface 1594 of the leading tooth 1574 extends from the tip1582 at a leading relief angle I relative to the plane 1534. In theillustrated embodiment, the leading relief angle I is approximately 25to 45 degrees.

As shown in FIG. 17, the tip 1582 of the leading tooth 1574 is spaced adistance U from the tip 1506 of the nearest cutting tooth 1450. Thedistance U is generally greater than a distance P (i.e., the pitch)between the tips 1506 of adjacent cutting teeth 1450. In the illustratedembodiment, the distance U is approximately twice the distance P. Assuch, the leading gullet 1590 is substantially larger than each gullet1514 of the cutting teeth 1450.

Although not shown, in some embodiments, each of the cutting teeth 1450may include a protrusion that inhibits a nail from entering the gullet1514 and contacting a rake face 1510 of an adjacent cutting tooth 1450.

FIGS. 18-19 illustrate a reciprocating saw blade 1630 according toanother embodiment of the invention. The illustrated saw blade 1630 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 1600.

The illustrated saw blade 1630 includes a body 1638, an attachmentportion 1642 for coupling the blade 1630 to a reciprocating saw, acutting portion 1646 having a plurality of cutting teeth 1650, and aplunge point 1654 for initiating a plunge cut. In the illustratedembodiment, the plunge point 1654 includes a leading tooth 1774, but nota second tooth. The leading tooth 1774 includes a tip 1782, a rake face1786 extending from the tip 1782 and at least partially defining aleading gullet 1790, and a relief surface 1794 extending from the tip1782 to an end 1798 of the body 1638. The rake face 1786 extends fromthe tip 1782 at a leading rake angle H relative to a plane 1734 definedby tips 1706 of the cutting teeth 1650. The leading rake angle H,measured through the leading tooth 1774, is a positive rake angle suchthat the leading tooth 1774 is a positive rake tooth havingsubstantially the same rake angle as each of the cutting teeth 1650. Inthe illustrated embodiment, the leading rake angle H is approximately 80to 88 degrees.

The relief surface 1794 of the leading tooth 1774 extends from the tip1782 at a leading relief angle I relative to the plane 1734. In theillustrated embodiment, the leading relief angle I is approximately 25to 45 degrees.

As shown in FIG. 19, the plunge point 1654 also includes a top edge 1802extending from the end 1798 of the body 1638 to a back portion 1774 ofthe body 1638. The illustrated top edge 1802 is an elongated edge thatis oriented at an angle G relative to the back portion 1774 such thatthe plunge point 1654 is a tapered plunge point. In some embodiments,the angle G is less than 15 degrees. In the illustrated embodiment, theangle G is approximately 8 degrees. The tapered plunge point 1654improves plunge cut performance by reducing the clearance required forthe saw blade 1630 to enter a work piece, thereby increasing cuttingspeed and improving cut accuracy and finish.

Although not shown, in some embodiments, each of the cutting teeth 1650may include a protrusion that inhibits a nail from entering a gullet1714 and contacting a rake face 1710 of an adjacent cutting tooth 1650.

FIGS. 20-21 illustrate a reciprocating saw blade 1830 according toanother embodiment of the invention. The illustrated saw blade 1830 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 1800.

The illustrated saw blade 1830 includes a body 1838, an attachmentportion 1842 for coupling the blade 1830 to a reciprocating saw, acutting portion 1846 having a plurality of cutting teeth 1850, and aplunge point 1854 for initiating a plunge cut. In the illustratedembodiment, the plunge point 1854 includes a leading tooth 1974, but nota second tooth. The leading tooth 1974 includes a tip 1982, a rake face1986 extending from the tip 1982 and at least partially defining aleading gullet 1990, and a relief surface 1994 extending from the tip1982 to an end 1998 of the body 1838. The rake face 1986 extends fromthe tip 1982 at a leading rake angle H relative to a plane 1934 definedby tips 1906 of the cutting teeth 1850. The leading rake angle H,measured through the leading tooth 1974, is a negative rake angle suchthat the leading tooth 1974 is a negative rake tooth. In the illustratedembodiment, the leading rake angle H is approximately 95 to 105 degrees.

As shown in FIG. 21, the tip 1982 of the leading tooth 1974 is spaced adistance U from the tip 1906 of the nearest cutting tooth 1850. Thedistance U is generally greater than a distance P (i.e., the pitch)between the tips 1906 of adjacent cutting teeth 1850. In the illustratedembodiment, the distance U is approximately twice the distance P. Assuch, the leading gullet 1990 is substantially larger than each gullet1914 of the cutting teeth 1850.

Although not shown, in some embodiments, each of the cutting teeth 1850may include a protrusion that inhibits a nail from entering the gullet1914 and contacting a rake face 1910 of an adjacent cutting tooth 1850.

FIGS. 22-23 illustrate a reciprocating saw blade 2030 according toanother embodiment of the invention. The illustrated saw blade 2030 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 2000.

The illustrated saw blade 2030 includes a body 2038, an attachmentportion 2042 for coupling the blade 2030 to a reciprocating saw, acutting portion 2046 having a plurality of cutting teeth 2050, and aplunge point 2054 for initiating a plunge cut. In the illustratedembodiment, the plunge point 2054 includes a leading tooth 2174, but nota second tooth. The leading tooth 2174 includes a tip 2182, a rake face2186 extending from the tip 2182 and at least partially defining aleading gullet 2190, and a relief surface 2194 extending from the tip2182 to an end 2198 of the body 2038. The rake face 2186 extends fromthe tip 2182 at a leading rake angle H relative to a plane 2134 definedby tips 2106 of the cutting teeth 2050. The leading rake angle H,measured through the leading tooth 2174, is a negative rake angle suchthat the leading tooth 2174 is a negative rake tooth. In the illustratedembodiment, the leading rake angle H is approximately 95 to 105 degrees.

As shown in FIG. 23, the tip 2182 of the leading tooth 2174 is spaced adistance U from the tip 2106 of the nearest cutting tooth 2050. Thedistance U is generally greater than a distance P (i.e., the pitch)between the tips 2106 of adjacent cutting teeth 2050. In the illustratedembodiment, the distance U is approximately twice the distance P. Assuch, the leading gullet 2190 is substantially larger than each gullet2114 of the cutting teeth 2050.

The plunge point 2054 also includes a top edge 2202 extending from theend 2198 of the body 2038 to a back portion 2074 of the body 2038. Theillustrated top edge 2202 is an elongated edge that is oriented at anangle G relative to the back portion 2074 such that the plunge point2054 is a tapered plunge point. In some embodiments, the angle G is lessthan 15 degrees. In the illustrated embodiment, the angle G isapproximately 8 degrees.

Although not shown, in some embodiments, each of the cutting teeth 2050may include a protrusion that inhibits a nail from entering the gullet2114 and contacting a rake face 2110 of an adjacent cutting tooth 2050.

FIGS. 24-25 illustrate a reciprocating saw blade 2230 according toanother embodiment of the invention. The illustrated saw blade 2230 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 2200.

The illustrated saw blade 2230 includes a body 2238, an attachmentportion 2242 for coupling the blade 2230 to a reciprocating saw, acutting portion 2246 having a plurality of cutting teeth 2250, and aplunge point 2254 for initiating a plunge cut. In the illustratedembodiment, the plunge point 2254 includes a leading tooth 2374, but nota second tooth. The leading tooth 2374 includes a tip 2382, a rake face2386 extending from the tip 2382 and at least partially defining aleading gullet 2390, and a relief surface 2394 extending from the tip2382 to an end 2398 of the body 2238. The rake face 2386 extends fromthe tip 2382 at a leading rake angle H relative to a plane 2334 definedby tips 2306 of the cutting teeth 2250. The leading rake angle H,measured through the leading tooth 2374, is a negative rake angle suchthat the leading tooth 2374 is a negative rake tooth. In the illustratedembodiment, the leading rake angle H is approximately 95 to 105 degrees.

As shown in FIG. 25, the tip 2382 of the leading tooth 2374 is spaced adistance U from the tip 2306 of the nearest cutting tooth 2050. In theillustrated embodiment, the distance U is generally the same as adistance P (i.e., the pitch) between the tips 2306 of adjacent cuttingteeth 2050. As such, the leading gullet 2390 is generally the same sizeas gullets 2314 defined by the plurality of cutting teeth 2050.

The plunge point 2254 also includes a top edge 2402 extending from theend 2398 of the body 2238 to a back portion 2274 of the body 2238. Theillustrated top edge 2402 is an elongated edge that is oriented at anangle G relative to the back portion 2274 such that the plunge point2254 is a tapered plunge point. In some embodiments, the angle G is lessthan 15 degrees. In the illustrated embodiment, the angle G isapproximately 8 degrees.

Although not shown, in some embodiments, each of the cutting teeth 2250may include a protrusion that inhibits a nail from entering the gullet2314 and contacting a rake face 2310 of an adjacent cutting tooth 2050.

FIGS. 26-27 illustrate a reciprocating saw blade 2430 according toanother embodiment of the invention. The illustrated saw blade 2430 issimilar to the saw blade 30 described above with reference to FIGS. 1-4,and similar parts have been given the same reference numbers, plus 2400.

The illustrated saw blade 2430 includes a body 2438, an attachmentportion 2442 for coupling the blade 2430 to a reciprocating saw, acutting portion 2446 having a plurality of cutting teeth 2450, and aplunge point 2454 for initiating a plunge cut. The plunge point 2454 issimilar to the plunge point 54 shown in FIGS. 1-4 and includes a leadingtooth 2574, a second tooth 2578, and an enlarged leading gullet 2590.However, in the illustrated embodiment, each cutting tooth 2450 does notinclude a protrusion.

FIG. 29 illustrates a saw blade 2634 according to another embodiment ofthe invention. The illustrated saw blade 2634 is a hole saw. The holesaw 2634 may be connected to a power tool, such as a drill, and rotatedabout a longitudinal axis 2638 to cut a hole in a work piece.

The hole saw 2634 includes a generally cylindrical body 2642 having anopen end 2646 and a closed end 2650. The open end 2646 defines a cuttingportion 2654 that engages the work piece during cutting. The closed end2650 is configured to mount to an arbor, or other suitable connectingstructure, to attach the hole saw 2634 to a power tool. Three openings2658 are formed in the body 2642 to facilitate chip and plug removalfrom the body 2642. The illustrated openings 2658 are completely boundby the body 2642 and angled relative to the longitudinal axis 2638. Inother embodiments, the body 2642 may define fewer or more openings 2658,and/or the openings 2658 may extend generally parallel to the axis 2638.In some embodiments, the openings 2658 may extend to and communicatewith the open end 2646 of the body 2642.

The cutting portion 2654 includes a plurality of cutting teeth 2662. Theillustrated cutting teeth 2662 are similar to the cutting teeth 50 shownin FIGS. 1-4, but, rather than being arranged in a straight line, arearranged in a continuous circle on the open end 2646 of the body 2642.Similar to the cutting teeth 50 discussed above, each cutting tooth 2662includes a tip 2666, a rake face 2670, a relief surface 2674, and aprotrusion 2678. The protrusions 2678 inhibit nails from enteringgullets 2682 between adjacent cutting teeth 2662 when the hole saw 2634is rotated in a cutting direction 2686 about the longitudinal axis 2638.In particular, the protrusions 2678 define a plane (similar to the plane158 of FIG. 3) that is at most spaced approximately 0.035 inches, andpreferably approximately 0.032 inches, from a plane (similar to theplane 134 of FIG. 3) defined by the tips 2666. In addition, eachprotrusion 2678 defines an effective relief surface (similar to theeffective relief surfaces 162 of FIG. 3) that is at most spacedapproximately 0.06 inches, and preferably approximately 0.05 inches,from an adjacent effective relief surface (if the body 2642 of the holesaw 2634 was flattened out). Other dimensions and angles of theillustrated cutting teeth 2662 may also be similar to the dimensions andangles of the cutting teeth 50 shown in FIG. 3.

Although particular embodiments embodying independent aspects of thepresent invention have been shown and described, other alternativeembodiments will become apparent to those skilled in the art and arewithin the intended scope of the independent aspects of the invention.For example, although the above saw blade tooth forms have beendescribed with reference to saw blades for use with reciprocating sawsthat alternately move the saw blades in cutting directions and returndirections, the tooth forms may be used on other types of saw bladeshaving a linear edge, including band saw blades and jig saw blades. Inaddition, the tooth forms may additionally be used on saw blades havinga curved edge, including circular saws blades.

Various features and advantages of the invention are set forth in thefollowing claims.

The invention claimed is:
 1. A reciprocating saw blade for use with areciprocating saw, the reciprocating saw blade comprising: a bodydefining a longitudinal axis; an attachment portion coupled to the body,the attachment portion including a tang and an aperture configured tocouple to the reciprocating saw; and a cutting portion formed on thebody, the cutting portion including a plurality of cutting teeth and aplurality of gullets positioned between the plurality of cutting teeth,each cutting tooth including a tip, a rake face extending from the tipgenerally toward the longitudinal axis and at least partially definingone of the plurality of gullets, a relief surface extending from thetip, and a protrusion extending from an end of the relief surfaceopposite the tip; wherein each gullet includes a base, a first curvedsurface extending from the rake face of a corresponding cutting tooth tothe base, and a second curved surface extending from the base to anadjacent cutting tooth, and wherein the protrusion of each cutting toothis located on the cutting tooth between the relief surface of thecutting tooth and the second curved surface of an adjacent gullet;wherein the tips of the plurality of cutting teeth define a first planethat is generally parallel to the longitudinal axis and the protrusionsof the plurality of cutting teeth define a second plane that isgenerally parallel to the longitudinal axis, and wherein a distancebetween the first plane and the second plane is at most approximately0.035 inches; and wherein a distance between the protrusion of onecutting tooth and the tip of an adjacent cutting tooth, measuredgenerally parallel to the longitudinal axis, is approximately 0.08inches.
 2. The reciprocating saw blade of claim 1, wherein the distancebetween the first plane and the second plane is approximately 0.032inches.
 3. The reciprocating saw blade of claim 1, wherein thereciprocating saw blade is configured to cut a work piece having a nailextending therethrough, and wherein the protrusion of each cutting toothinhibits the nail from entering the gullet and contacting the rake faceof an adjacent cutting tooth during cutting operations.
 4. Thereciprocating saw blade of claim 1, wherein adjacent cutting teeth ofthe plurality of cutting teeth are separated by a pitch of approximately0.2 inches.
 5. The reciprocating saw blade of claim 1, wherein theprotrusion of each cutting tooth is generally rounded.
 6. Thereciprocating saw blade of claim 1, wherein the relief surface of eachcutting tooth includes a first end that is closer to the attachmentportion and a second end that is further from the attachment portion,and wherein the tip of each cutting tooth is formed at the first end ofthe relief surface and the protrusion of each cutting tooth extends fromthe second end of the relief surface.
 7. A reciprocating saw blade foruse with a reciprocating saw, the reciprocating saw blade comprising: abody defining a longitudinal axis; an attachment portion coupled to thebody, the attachment portion including a tang and an aperture configuredto couple to the reciprocating saw; and a cutting portion formed on thebody, the cutting portion including a plurality of cutting teeth and aplurality of gullets positioned between the plurality of cutting teeth,each cutting tooth including a tip, a rake face extending from the tipgenerally toward the longitudinal axis and at least partially definingone of the plurality of gullets, a relief surface extending from thetip, and a protrusion extending from an end of the relief surfaceopposite the tip, each cutting tooth defining an effective reliefsurface that extends from the tip and is tangent to the protrusion;wherein each gullet includes a base, a first curved surface extendingfrom the rake face of a corresponding cutting tooth to the base, and asecond curved surface extending from the base to an adjacent cuttingtooth, and wherein the protrusion of each cutting tooth is located onthe cutting tooth between the relief surface of the cutting tooth andthe second curved surface of an adjacent gullet; wherein a distancebetween effective relief surfaces of adjacent cutting teeth is at mostapproximately 0.06 inches.
 8. The reciprocating saw blade of claim 7,wherein the distance between effective relief surfaces of adjacentcutting teeth is approximately 0.05 inches.
 9. The reciprocating sawblade of claim 7, wherein the tips of the plurality of cutting teethdefine a plane that is generally parallel to the longitudinal axis, andwherein the effective relief surface of each cutting tooth intersectsthe plane at an angle of approximately 14.5 degrees.
 10. Thereciprocating saw blade of claim 7, wherein the reciprocating saw bladeis configured to cut a work piece having a nail extending therethrough,and wherein the protrusion of each cutting tooth inhibits the nail fromentering the gullet and contacting the rake face of an adjacent cuttingtooth during cutting operations.
 11. The reciprocating saw blade ofclaim 7, wherein adjacent cutting teeth of the plurality of cuttingteeth are separated by a pitch of approximately 0.2 inches.
 12. Thereciprocating saw blade of claim 7, wherein the protrusion of eachcutting tooth is generally rounded.
 13. The reciprocating saw blade ofclaim 7, wherein the relief surface of each cutting tooth includes afirst end that is closer to the attachment portion and a second end thatis further from the attachment portion, and wherein the tip of eachcutting tooth is formed at the first end of the relief surface and theprotrusion of each cutting tooth extends from the second end of therelief surface.
 14. The reciprocating saw blade of claim 13, wherein therelief surface of each cutting tooth extends approximately 0.1 inchesfrom the first end to the second end.
 15. A reciprocating saw blade foruse with a reciprocating saw, the reciprocating saw blade comprising: abody defining a longitudinal axis; an attachment portion coupled to thebody, the attachment portion including a tang and an aperture configuredto couple to the reciprocating saw, the attachment portion being angledrelative to the longitudinal axis by a tang angle; and a cutting portionformed on the body, the cutting portion including a plurality of cuttingteeth and a plurality of gullets positioned between the plurality ofcutting teeth, each cutting tooth including a tip, a rake face extendingfrom the tip generally toward the longitudinal axis and at leastpartially defining one of the plurality of gullets, a relief surfaceextending from the tip, and a protrusion extending from an end of therelief surface opposite the tip, each cutting tooth defining aneffective relief surface that extends from the tip and is tangent to theprotrusion; wherein each gullet includes a base, a first curved surfaceextending from the rake face of a corresponding cutting tooth to thebase, and a second curved surface extending from the base to of anadjacent cutting tooth, and wherein the protrusion of each cutting toothis located on the cutting tooth between the relief surface of thecutting tooth and the second curved surface of an adjacent gullet;wherein the tips of the plurality of cutting teeth define a plane thatis generally parallel to the longitudinal axis, wherein the reliefsurface of each cutting tooth intersects the plane at a relief angle andthe effective relief surface of each cutting tooth intersects the planeat an effective relief angle, and wherein the effective relief angle hasa value that is between a value of the tang angle and a value of therelief angle.
 16. The reciprocating saw blade of claim 15, wherein thetang angle is approximately 6.5 degrees and the relief angle of eachcutting tooth is approximately 23 degrees.
 17. The reciprocating sawblade of claim 16, wherein the effective relief angle of each cuttingtooth is approximately 14.5 degrees.
 18. The reciprocating saw blade ofclaim 15, wherein a ratio between the relief angle and the effectiverelief angle of each cutting tooth is approximately 1.6.
 19. Thereciprocating saw blade of claim 15, wherein a ratio between theeffective relief angle, in degrees, of each cutting tooth and adistance, in inches, between effective relief surfaces of adjacentcutting teeth is approximately
 290. 20. The reciprocating saw blade ofclaim 15, wherein a ratio between a distance from the protrusion of onecutting tooth to the tip of an adjacent cutting tooth, measuredgenerally parallel to the longitudinal axis, and a distance betweeneffective relief surfaces of adjacent cutting teeth is approximately1.6.
 21. The reciprocating saw blade of claim 15, wherein thereciprocating saw blade is configured to cut a work piece having a nailextending therethrough, and wherein the protrusion of each cutting toothinhibits the nail from entering the gullet and contacting the rake faceof an adjacent cutting tooth during cutting operations.
 22. Thereciprocating saw blade of claim 15, wherein adjacent cutting teeth ofthe plurality of cutting teeth are separated by a pitch of approximately0.2 inches.
 23. The reciprocating saw blade of claim 15, wherein theprotrusion of each cutting tooth is generally rounded.
 24. Thereciprocating saw blade of claim 15, wherein the relief surface of eachcutting tooth includes a first end that is closer to the attachmentportion and a second end that is further from the attachment portion,and wherein the tip of each cutting tooth is formed at the first end ofthe relief surface and the protrusion of each cutting tooth extends fromthe second end of the relief surface.
 25. A reciprocating saw blade foruse with a reciprocating saw, the reciprocating saw blade configured tocut a work piece having a nail extending therethrough, the reciprocatingsaw blade comprising: a body defining a longitudinal axis; an attachmentportion coupled to the body, the attachment portion including a tang andan aperture configured to couple to the reciprocating saw, theattachment portion being angled relative to the longitudinal axis by atang angle; and a cutting portion formed on the body, the cuttingportion including a plurality of cutting teeth and a plurality ofgullets positioned between the plurality of cutting teeth, each cuttingtooth including a tip, a rake face extending from the tip generallytoward the longitudinal axis and at least partially defining one of theplurality of gullets, a relief surface extending from the tip, and aprotrusion extending from an end of the relief surface opposite the tip,the protrusion of each cutting tooth inhibiting the nail from enteringthe gullet and contacting the rake face of an adjacent cutting toothduring cutting operations, each cutting tooth defining an effectiverelief surface that extends from the tip and is tangent to theprotrusion; wherein each gullet includes a base, a first curved surfaceextending from the rake face of a corresponding cutting tooth to thebase, and a second curved surface extending from the base to an adjacentcutting tooth, and wherein the protrusion of each cutting tooth islocated on the cutting tooth between the relief surface of the cuttingtooth and the second curved surface of an adjacent gullet; wherein thetips of the plurality of cutting teeth define a first plane that isgenerally parallel to the longitudinal axis and the protrusions of theplurality of cutting teeth define a second plane that is generallyparallel to the longitudinal axis, wherein a distance between the firstplane and the second plane is at most approximately 0.035 inches;wherein a distance between effective relief surfaces of adjacent cuttingteeth is at most approximately 0.06 inches; and wherein the reliefsurface of each cutting tooth intersects the first plane at a reliefangle and the effective relief surface of each cutting tooth intersectsthe first plane at an effective relief angle, and wherein the effectiverelief angle has a value that is between a value of the tang angle and avalue of the relief angle.
 26. The reciprocating saw blade of claim 25,wherein the distance between the first plane and the second plane isapproximately 0.032 inches.
 27. The reciprocating saw blade of claim 26,wherein a distance between the protrusion of one cutting tooth and thetip of an adjacent cutting tooth, measured generally parallel to thelongitudinal axis, is approximately 0.08 inches.
 28. The reciprocatingsaw blade of claim 25, wherein the distance between effective reliefsurfaces of adjacent cutting teeth is approximately 0.05 inches.
 29. Thereciprocating saw blade of claim 25, wherein the tang angle isapproximately 6.5 degrees and the relief angle of each cutting tooth isapproximately 23 degrees.
 30. The reciprocating saw blade of claim 29,wherein the effective relief angle of each cutting tooth isapproximately 14.5 degrees.
 31. The reciprocating saw blade of claim 25,wherein adjacent cutting teeth of the plurality of cutting teeth areseparated by a pitch of approximately 0.2 inches.
 32. The reciprocatingsaw blade of claim 25, wherein the protrusion of each cutting tooth isgenerally rounded.